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Marlo Incorporated MR Series Installation, Operation And Maintenance Manual

Plc controller commercial water conditioners
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PLC CONTROLLER
COMMERCIAL WATER CONDITIONERS
COMPLETE FOR FUTURE REFERENCE:
MODEL NO:
SERIAL NO:
DATE INSTALLED:
DEALER:
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
MR 150–1050M
Marlo Incorporated
2227 South Street
P.O. Box 044170
Racine, WI 53404-7003
www.Marlo-Inc.com
8-217 R5

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Summary of Contents for Marlo Incorporated MR Series

  • Page 1 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL MR 150–1050M PLC CONTROLLER COMMERCIAL WATER CONDITIONERS COMPLETE FOR FUTURE REFERENCE: MODEL NO: Marlo Incorporated SERIAL NO: 2227 South Street P.O. Box 044170 DATE INSTALLED: Racine, WI 53404-7003 DEALER: www.Marlo-Inc.com 8-217 R5...
  • Page 2 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER IMPORTANT PLEASE READ: � Warranty of this product extends to manufacturing defects. � The information, specifications and illustrations in this manual are based on the latest information available at the time of printing. The manufacturer reserves the right to make changes at any time without notice.
  • Page 3 MR 150M–1050M - PLC CONTROLLER TABLE OF CONTENTS Water Treatment Product Warranty and Softener Guarantee Specification General Arrangement Drawing INSTALLATION Piping Installation ________________________________________________________________ OPERATION Start Up Instructions________________________________________________________________ _________________________________________________ __ ________________________________________________________ ________________________________________________________ _________________________________________________________ ____________________________________________________________ MAINTENANCE Electrical Controls Drawings_________________________________________________________ Replacement Valve Table __________________________________________________________ Diaphragm Valve Repair Kits _________________________________________________________ Signet Flow Sensor ________________________________________________________________ Brine Assemblies __________________________________________________________________...
  • Page 4 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER SYSTEM INFORMATION PRODUCT WARRANTY Manufacturer's warrants all water treatment products manufactured and / or distributed by it to be free from defects in materials and workmanship for a period of one (1) year from the date of shipment.
  • Page 5 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER SYSTEM INFORMATION SPECIFICATION NOTES Maximum salting is 15 pounds of salt per cubic foot of resin. This setting gives the longest time between regenerations. It has an efficiency of 2,000 grains of hardness removed per pound of salt.
  • Page 6 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER SYSTEM INFORMATION SPECIFICATION TABLE MODEL 1050 Valve Size inches 1050 Capacity (Kgrains) Cont’s. Service Peak Backwash & Flush Brine Draw & Rinse Pins Backwash Minutes Pins Brine Draw & Rinse Minutes Pins Fast Flush Minutes Pins...
  • Page 7 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER INSTALLATION SYSTEM INFORMATION Page 4...
  • Page 8 MR 150M–1050M PLC INSTALLATION MR 150M–1050M - PLC CONTROLLER INSTALLATION INSTALLATION DIMENSIONS AND SPECIFICATIONS Approx. Length Brine Drain Pipe Width MODEL Height Pipe Size Pipe Size Size (Inches) (inches) (inches) (inches) (inches) Single Twin Triple MR-150-1 MR-150-1 1  MR-150-1 1...
  • Page 9 MR 150M–1050M PLC INSTALLATION MR 150M–1050M - PLC CONTROLLER INSTALLATION SOFTENER INSTALLATION INSTRUCTIONS GENERAL INFORMATION Before beginning installation, thoroughly review the following instructions to familiarize yourself with the general placement and identification of all components. These instructions are written for a single unit installation, but they also generally apply to twin and triple units.
  • Page 10 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER INSTALLATION INSTALLATION PIPING INSTALLATION Note: • Install the piping conforming to federal, provincial, and local codes. • Union or flanges are recommended at the control valve's inlet, outlet, and drain connections • To enhance the monitoring of the system's performance sample valves and pressure gauges can be installed at the inlet and outlet piping to each control valve.
  • Page 11 MR 150M–1050M - PLC CONTROLLER INSTALLATION TUBING DIAGRAM - VALVE NEST - MULTITANK - ASCO SOLENOID...
  • Page 12 MR 150M–1050M - PLC CONTROLLER INSTALLATION TUBING DIAGRAM - VALVE NEST - MULTITANK - PARKER SOLENOID...
  • Page 13 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER INSTALLATION INSTALLATION BRINE TANK INSTALLATION TO INJECTOR EXTENSION TO INJECTOR OVERFLOW (PIPE TO DRAIN) FLOAT BRINE WELL DRY SALT STORAGE FLOAT BRINE VALVE FLOAT HEIGHT SALT SHELF LIQUID BRINE BRINE VALVE 1. The brine tank is placed as shown on the installation drawing, on a smooth level surface. If not, the tank should be placed on a smooth piece of exterior plywood and leveled by placing shims beneath the plywood.
  • Page 14 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER INSTALLATION INSTALLATION SOFTENER TANK LOADING GRAVEL LOADING UPPER DISTRIBUTOR 1. See the Specification Table on page 3 for the correct amount of gravel and resin. Do not begin loading until you have confirmed all of the required media is on site.
  • Page 15 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER OPERATION OPERATION START-UP INSTRUCTIONS PLC PROGESSIVE CONTROLLER Note: Read the controls description section located in this manual before proceeding. With all piping and installation complete, and the mineral in the tank, proceed as follow: 1.
  • Page 16 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER OPERATION OPERATION 7. Advance Unit 1 to the backwash step. The unit 1 stager should rotate to the step 1 (backwash) position. 8. Slowly open the manual inlet supply valve. Do not open fully. Full flow of water could cause loss of media.
  • Page 17 MR 150M–1050M - PLC CONTROLLER OPERATION ELECTRICAL CONTROLS OPERATION General-the main control panel (MCP) contains the programmable logic controller (PLC) and the operator interface (OIT). The system is controlled by the PLC. Operator intervention and control along with some program set point access is through the OIT. The PLC controls the system so that one or more units will be online (in service) based on flow demand.
  • Page 18 MR 150M–1050M - PLC CONTROLLER OPERATION OPERATOR INTERFACE SCREENS SUMMARY SCREEN 1-MAIN SCREEN 2-CYCLE TIMES/BATCH/K-FACTOR (PRESETS 1) SCREEN 3-MANUAL START/REGENERATION ADVANCE SCREEN 4-REGEN START CHOICE AND ELAPSED TIME OVERRIDE SCREEN 5-FLOW DELAY PRESETS & FLOW RATE SETPOINTS SCREEN 6-TOTALIZERS SCREEN 7-SYSTEM RESET/CONFIGURATION SCREEN 8-SCREEN CHANGES SCREEN 9-ALARM HISTORY ALL SCREENS ARE NOT SECURED...
  • Page 19 MR 150M–1050M - PLC CONTROLLER OPERATION SCREEN 1- MAIN SCREEN The main screen displays the following: Last Regen- the field below the unit identifier will indicated how that unit regenerated the last time it went into regen: batch, time or manually. Unit Status- each unit is identified as A &...
  • Page 20 MR 150M–1050M - PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 2- CYCLE TIME/BATCH/K-FACTOR PRESETS SCREEN This screen can be used to change the following set points: Backwash time in minutes Brine inj/Slow rinse time in minutes Fast rinse time in minutes Batch- This is the amount of gallons that can pass through a unit before it needs to be regenerated.
  • Page 21 MR 150M–1050M - PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 3- MANUAL REGENERATION START/ADVANCE This is the main screen used for manual operator regeneration start and advance. It is mainly used to manually start and advance a unit through it regeneration steps. Once a manual regeneration start is begun, regeneration cycle timing is automatic and the unit will advance automatically through the regeneration steps.
  • Page 22 MR 150M–1050M - PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 4- REGEN START CHOICE AND ELAPSED TIME OVERRIDE This screen is used to select how the softener system will regenerate. The blue list selector box on the left side of this screen is used to show which method will be used to regenerate the softener system.
  • Page 23 MR 150M–1050M - PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 5- FLOW DELAY PRESETS & FLOW RATE PRESETS SCREEN This screen can be used to change the following set points: Delay time (seconds) before the second unit will be added due to flow exceeding the “add second unit set point”.
  • Page 24 MR 150M–1050M - PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 6-TOTALIZERS This screen is used to view the number of gallons have passed for any unit while it was in service. To reset any units’ totalizer press the corresponding button at the bottom of the screen. -There is a 3 second delay on the totalizer reset buttons to verify operator intent.
  • Page 25 MR 150M–1050M - PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 7- SYSTEM RESET & CONFIG ACCESS This screen allows the system to be reset or allows access to the configuration of the OIT. System reset-this button when depressed for a minimum of 5 continuous seconds will reset the system.
  • Page 26 MR 150M–1050M - PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 8- SCREEN CHANGES This screen can be used to change to a different screen.
  • Page 27 MR 150M–1050M - PLC CONTROLLER OPERATION CONTROLS CONTINUED: OPERATOR INTERFACE SCREENS SCREEN 9- ALARM HISTORY/BANNER An alarm banner will occur if:  any of the stagers in the LCP’s fail to rotate home.  Flow is detected on the unit in standby ...
  • Page 28 MR 150M–1050M - PLC CONTROLLER OPERATION CONTROLS CONTINUED OPERATOR INTERFACE SCREENS Screen Saver- after 10 minutes of no activity on the screen, the screen will go blank. This is the screen saver. Press any key on the OIT and the screens will come back on. STAGER OPERATION STAGERS-Each stager is located in its own enclosure on the individual units themselves.
  • Page 29 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER OPERATION OPERATION HOW TO CALCULATE SOFTENERS CAPACITY “Batch size” is the term used for the amount of water passing through and being softened by the water softener between regenerations. This is a simple calculation provided two pieces of information are known: •...
  • Page 30 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER OPERATION OPERATION WATER SOFTENER GENERAL OPERATION Hard water passes through the valve manifold into the top of the softener tank. It flows downward through the mineral bed and out through the bottom of the tank to service. As the water passes through the mineral bed, the hardness present is removed through the process of ion exchange and at the same time sediment present is removed by filtration action of the mineral.
  • Page 31 MR 150M–1050M PLC OPERATION MR 150M–1050M - PLC CONTROLLER OPERATION FLOW DIAGRAM Page 28 PAGE...
  • Page 32 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER OPERATION OPERATION BRINE MAKER OPERATION The brine-maker is an automatic brining system, which is easily adjusted to provide maximum TO INJECTOR operating efficiency of your water softener. It is a OVERFLOW combination salt storage and brine-measuring tank (PIPE TO DRAIN) complete with an automatic valve.
  • Page 33 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER OPERATION OPERATION MINIMUM SALTING ADJUSTMENT Minimum salting is the most efficient use of salt. But it does minimize the capacity of the unit, which will decrease the time between regenerations. Only make this adjust after the unit has completed a brine tank refill step and the water level was checked to be above the salt platform.
  • Page 34 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER OPERATION OPERATION Flow Rate Trip Point Table Program Values for A, B, C & D MODEL Alternating Operation Parallel Operation (gpm) (gpm) Second Unit Trip Second Unit Trip *Third Unit Trip Flow Range Flow Range Flow Range Exchange...
  • Page 35 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER OPERATION OPERATION K FACTOR Table Program values for XX PIPE SIZE SADDLE SADDLE WELDOLET (Inches) Galvanized Iron Carbon Steel 1 1/4 1 1/2 2 1/2 Page 32 PAGE...
  • Page 36 MR 150M–1050M - PLC CONTROLLER MAINTENANCE...
  • Page 37 MR 150M–1050M - PLC CONTROLLER MAINTENANCE...
  • Page 38 MR 150M–1050M - PLC CONTROLLER MAINTENANCE...
  • Page 39 MR 150M–1050M - PLC CONTROLLER MAINTENANCE...
  • Page 40 MR 150M–1050M - PLC CONTROLLER MAINTENANCE...
  • Page 41 MR 150M–1050M - PLC CONTROLLER MAINTENANCE...
  • Page 42 MR 150M–1050M - PLC CONTROLLER MAINTENANCE...
  • Page 43 MR 150M–1050M - PLC CONTROLLER MAINTENANCE Replacement Valve Table Location# Function Position Service Inlet NORMALLY OPEN Service Outlet NORMALLY OPEN Bypass Valve - NORMALLY CLOSED Single Systems Only Backwash Outlet NORMALLY OPEN Backwash Inlet NORMALLY OPEN NORMALLY OPEN Brine Inlet SPRING ASSIST OPEN NORMALLY OPEN Brine/Flush Outlet...
  • Page 44 MR 150M–1050M PLC MAINTENANCE MR 150M–1050M - PLC CONTROLLER MAINTENANCE AQUAMATIC REPAIR KITS RA - Diaphragm & Seal Kits - Includes Buna N Seals and Diaphragm (Items 3(2),5,6,8(2),9,14&16) RF - Metal Parts Kit (Normally Open) - (Items 4,7,10,11(2), 17) RG - Metal Parts Kit (Normally Closed) - (Items 4,7,10,11(2), 23) SC - Repair Kit (Spring Assist Closed) - (Items 24,27,28) SO - Repair Kit (Spring Assist Open) - (Items 8,31,32) GT - Tool - To Install &...
  • Page 45 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER MAINTENANCE MAINTENANCE 2536 Standard Mount Sensor Galvanized Iron Threaded Tee with NPT Threads PVDF Insert Iron Strap-on Saddle with PVDF Insert K- Factor Table (Pulses per Gallon) Pipe Size Saddle Inches Galvanized Iron 1-1/4 1-1/2...
  • Page 46 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER MAINTENANCE MAINTENANCE BRINE SYSTEM FOR MGT 150-450 Models Part Number Shelf Height MR 150 B1039001 15" MR 210 B1039002 22" MR 300 B1039003 29" MR 450 B1039009 29" Item Number Part Number Item Description B1002007 BRINE TANK W/HOLES 24x50-MR 150-210...
  • Page 47 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER MAINTENANCE MAINTENANCE BRINE SYSTEM FOR MGT 600-1050 Models Part Number Shelf Height MR 600 B1039005 22" MR 750 B1039005 22" MR 900 B1039007 29" MR 1050 B1039008 22" Item Number Part Number Item Description B1002010 BRINE TANK W/HOLES 39x60 - (MR 600-750)
  • Page 48 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER MAINTENANCE MAINTENANCE SERVICE CHART STAGER CONTROLLER SYMPTOM PROBABLE CAUSE HOW TO CORRECT 1. No electrical power. Check circuit. Start a regeneration with Manual Regeneration Lever. 2. Frequency levers on Time Dial not Refer to “How to Set set properly.
  • Page 49 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER MAINTENANCE MAINTENANCE SERVICE CHART WATER SOFTENERS IMPORTANT: Many softener complaints result from oversights (poor electric connections, out of salt, regenerating at wrong hour etc.) rather than from a mechanical failure. Troubleshooting guide for the MX controller is located in the back of this manual page 33.
  • Page 50 MR 150M–1050M PLC MR 150M–1050M - PLC CONTROLLER MAINTENANCE MAINTENANCE SERVICE CHART WATER SOFTENERS continued PROBLEM OR CHECK PROCEDURE CAUSE SYMPTOM If vent hole is plugged, a partial vacuum will be created in the space between the 14. Check that vent hole is not plugged. diaphragm and shaft guide, preventing Diaphragm valve does valve from opening.
  • Page 51 MR 150M–1050M - PLC CONTROLLER NOTES...
  • Page 52 2227 South Street • P.O. Box 044170 • Racine, WI 53404-7003 • www.Marlo-Inc.com 8-217 R5...

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